Once this was dried I made another cut on the other side to completely free the blocks that were going to become drawers. I spread glue carefully over the ends of the divider portions and glued the previously removed side back on. If you look at the third picture you can see this set of cuts and which sections are drawers and which are dividers. I determined my final block dimensions anticipating the 1/16" that would be eaten up by the blade with each cut, so I made each cut measurement from the last cut. In my design I wanted drawers that were 1 1/2" tall with 3/8" dividers in between them. These cuts mark where the top and bottom of each drawer are going to be, so they should be measured carefully and cut straight. I then made nine cuts from the side inwards and stopped about 3/8" away from going all the way through.
To do this, I cut off one side of the box, removing about the same thickness, and set that aside. With the back removed, the next task was to remove the five chunks from the middle of this box that will become the drawers. It is best to avoid sanding the cut faces right now because most of them will get glued back together. I scribed a line and cut about 3/8" off the back and set that aside. The first step was to cut the back of the box off. Throughout the whole process it is easy to get caught up and make the wrong cut, so be careful, and make sure your bandsaw blade is straight. There are a lot of cuts going on here, so do your best to try and follow. The rest of the dimensions unfolded from there. The final design had four 1.5" drawers, each with 3/8" dividers in between them, and a 1" drawer at the very bottom. With these parameters in mind, I determined the final dimensions of this block had to be about 6" x 4" x 10".
Also, for convenience, I didn't want to make the box deeper than the spindle/belt sander was going to be able to reach, since this is the primary tool for flushing edges and flattening surfaces. Neither the depth nor the width of the box can be higher than the maximum cutting height of the bandsaw. I was intent on flocking the insides of the drawers, so I decided to use the top trim to create a sort of tray that would also be flocked.Ī bandsaw box is unique because the entire box and drawers are cut from one big block of wood, which means there are some size limitations. The bottom trim would be thick enough to conceal a shallow, secret, spring-loaded drawer. My idea was to make a tall, rectangular bandsaw box with a couple drawers and some trim on the top and bottom.